Need some help with Hella lights wiring,

[maddevildog]

Hello guys,
I am in need of some help and i am hoping i can get it here. I installed a set of Hella 500 FF lights today and can not get these darn things to work. The instructions are not the greatest but as far as i can tell I have everything wired correctly. I called their tech support today and for lack of better words it was a pain in the butt and did not get anything resolved.

Here is my issue, they will not turn on, the switch will not light up and i keep blowing the inline fuse to the switch. Here is how it is wired:

Red wire to the battery from the relay
Black wires from lights to the relay and the lights are grounded
yellow wire from the relay to the switch
blue wire from the relay is grounded
green wire from the batter to the switch (this way i can turn on whenever i want)
switch is grounded

The switch that came with the kit i was told was bad from their tech support because it would not light, but i did have 12 VDC at the switch and the fuse did not blow. When i turned the switch on and off i did not have any VDC from the yellow wire off the switch. I bought a new switch today and as soon as i turned the switch on it lite for a split second then blew the green inline fuse from the switch to the battery. I added pics with both switches as well

Any help would be great guys.






Thanks,
DJ

 

[maddevildog]

I currently have the second switch hooked up right now (with labels) when i switch the yellow and green the inline fuse of the green wire pops immediately.

 

[TNRunner99]

Make sure your ground is good. Are both wires going to the battery for the Hellas? I only remember having one when I had mine.

 

[maddevildog]

Make sure your ground is good. Are both wires going to the battery for the Hellas? I only remember having one when I had mine.

Yeah, The red is the 12V and the green goes to the switch. The green should be tapped into the high beam wire but I have it coming from the battery so it is always hot. This would allow me (i think) to turn the lights on and off whenever I wanted to but, but if i forget to turn them off it will drain my battery.

 

[TNRunner99]

Yeah, The red is the 12V and the green goes to the switch. The green should be tapped into the high beam wire but I have it coming from the battery so it is always hot. This would allow me (i think) to turn the lights on and off whenever I wanted to but, but if i forget to turn them off it will drain my battery.

I would say the switch doesn't need to be straight off the battery. I used a Toyota switch for mine and its tapped into the fuse box. Works fine. Did the Hella diagram show wiring it to the battery?

 

[maddevildog]

After checking everything again (20th time) i think i found the problem. My light kit was missing the relay when i got it, the store took one from the black out kit. The instructions in the 500 FF shows the relay number placement different from the relay i got from the store when they took the other from the box. The red and yellow are in different spots, went back to the store and they are ordering another 500 FF kit to check the relays.

 

[KidVermicious]

If they're both four pin relays, it shouldn't matter. Here's a diagram I stole from somewhere else:

The way relays work, there's two paths through them. There's the "switch" path, which is pins 85 and 86, and there's the "power" path, which is pins 30 and 87 (notice that pin 30 has a different orientation, so you know which is which). When the relay is not powered there is no continuity between pins 30 and 87. When you put 12v across pins 85 and 86, this energizes the relay into closing the path between 30 and 87. And it doesn't matter which way electricity is flowing - the relay doesn't care. So you can wire your switch to either 85 or 86, and as long as the other side goes to ground, it'll work. And you can bring your power source in on 30 or 87, and as long as the other side goes to your lights (and then to ground), it'll work. Put a fuse between the battery and the relay (as close to the battery as you can), and as long as you're not shorted across terminals or shorted to ground somewhere, it'll work. If you're wired exactly like the diagram I posted and are still blowing fuses, then you're shorted somewhere.